System, method, and apparatus for magnetic surface coverings

ABSTRACT

The present invention pertains to the art of floor coverings, and, more particularly to an apparatus for use in securing floor covering units to an underlay and a method of manufacturing said floor covering units and said underlay. More particularly, the present invention relates to an apparatus, method, and method of manufacturing magnetized floor covering units and magnetized underlays for securing magnetized floor covering units.

CROSS-REFERENCE AND RELATED APPLICATIONS

The present invention is related to SYSTEM, METHOD, AND APPARATUS FORMAGNETIC SURFACE COVERINGS, by Lautzenhiser et al., U.S. applicationSer. No. 15/083,225, filed Mar. 28, 2016, and claims priority to U.S.Provisional Patent Applications U.S Provisional Patent App. No.61/139,226, entitled SYSTEM, METHOD, AND APPARATUS FOR THE MANUFACTUREAND INSTALLATION OF MAGNETIC FLOOR COVERING UNITS AND MAGNETICUNDERLAYS, by Lautzenhiser et al., filed Mar. 27, 2015, and to U.SProvisional Patent App. No. 62/258,432, entitled SYSTEM AND METHOD FORMAGNETIC WALL COVERING UNITS AND MAGNETIC UNDERLAYS, by Lautzenhiser etal., filed Nov. 21, 2015, all of which are incorporated by referenceherein in their entirety.

FIELD OF THE INVENTION

The present invention pertains to the art of floor and wall coverings,and, more particularly to an apparatus for use in securing floorcovering units to an underlay and a method of manufacturing said floorcovering units and said underlay and to a system and method for use insecuring wall covering units to an underlay and a method of securing anunderlay to a wall board.

BACKGROUND

A magnet is a material that can exert a noticeable force on othermaterials without actually contacting them. This force is known as amagnetic force and may either attract or repel. While all knownmaterials exert some sort of magnetic force, it is so small in mostmaterials that it is not readily noticeable. With other materials, themagnetic force is much larger, and these are referred to as magnets.Some magnets, known as permanent magnets, exert a force on objectswithout any outside influence. The iron ore magnetite, also known aslodestone, is a natural permanent magnet. Other permanent magnets can bemade by subjecting certain materials to a magnetic force. When the forceis removed, these materials retain their own magnetic properties.Although the magnetic properties may change over time or at elevatedtemperatures, these materials are generally considered to be permanentlymagnetized, hence the name.

All magnets have two points where the magnetic force is greatest. Thesetwo points are known as the poles. For a rectangular or cylindrical barmagnet, these poles would be at opposite ends. One pole is called thenorth-seeking pole, or North Pole, and the other pole is called thesouth-seeking, or South Pole. This terminology reflects one of theearliest uses of magnetic materials such as lodestone. When suspendedfrom a string, the north pole of these first crude compasses wouldalways “seek” or point towards the north. This aided sailors in judgingthe direction to steer to reach distant lands and return home.

Currently magnet applications include compasses, electric motors,microwave ovens, coin-operated vending machines, light meters forphotography, automobile horns, televisions, loudspeakers, and taperecorders. A simple refrigerator note holder and a complex medicalmagnetic resonance imaging device all utilize magnets.

When making magnets, the raw materials are often more important than themanufacturing process. The materials used in permanent magnets(sometimes known as hard materials, reflecting the early use of alloysteels for these magnets) are different than the materials used inelectromagnets.

In the field of modular floor covering unit installation, existingmethods of installing such floor coverings typically involve a verylabor and material intensive process. The process involves individuallygluing down floor covering units using an adhesive. The adhesive isheavy, difficult to apply, costly, difficult to remove, and prone tofailure. Using the prior art method, adhesive must be applied to theentire supporting surface or the entire underside of a floor coveringunit. This process is costly in both labor and money and createsadditional costs if floor covering units are to be replaced or removed.

Another method known in the art for installing modular floor coveringunits involves using adhesive connectors to connect modular floorcovering units with adjacent units. Such “connector systems” of theprior art allow the modular floor covering to “float” on top of thesupporting surface. These prior art systems use an adhesive to hold theedges of the adjacent flooring units together. One such system andmethod is the SYSTEM FOR CARPET TILE INSTALLATION, U.S. Pat. No.8,434,282, issued May 7, 2013 (Scott et al.), which is incorporatedherein by reference in its entirety. The method described in Scott etal. utilizes a one sided pressure sensitive adhesive tab that isapproximately 72 mm square that has a releasable protective layer tojoin four sections of modular flooring units together. There a severalproblems with using this method to install a modular floor covering.

The modular flooring units are typically heavy in nature and the bondbetween the tile connector and modular flooring unit is relatively weakcompared to traditional adhesives. In the Scott et al. tile connector,the connector is formed from an inert plastic that is coated with anadhesive. Although the connector is water resistant, it is notcompletely waterproof. This may cause the connector to fail under someconditions. Floor covering units are constantly under attack frommoisture. The Scott et al. prior art claims the connectors are waterresistant because the connectors only have adhesive on one side, theupwards facing side, making the connector less susceptible to moisturefrom the subfloor. However, this ignores adhesive failure from moisturesources above the connector. For example, a business such as a hotel maysteam clean the floor covering unit connected by a Scott et al. typeadhesive connector. Further the floor frequently may have liquidsspilled on it and may experience wet winter conditions. This “wetting”occurs from above and moisture leeches down onto the face of the priorart connector, making it highly susceptible to moisture and potentialconnector failure.

The Scott et al. type prior art tile connectors have a high rate offailure in areas of heavy traffic and along modular flooring unit seams.Heavier traffic from office equipment, foot traffic, chairs etc. puts astrain on these connectors. The strain from heavier traffic may causethe connectors to fail in one or more ways.

The first type of failure for the Scott et al. type adhesive connectorsis that the glue will stretch or fail under a heavy force such a chairrolling or other heavy object being moved across the floor covering. Toaddress this problem, modular floor covering installers may use a sprayadhesive in a can to supplement this type of adhesive connector systemto give the seams of the modular floor covering extra strength. However,doing so removes most of the advantages of this type of connector systemand introduces volatile organic chemicals (“VOCs”) into the installationarea. VOCs present in the installation area require at a minimumadditional ventilation and may also necessitate installing the modularfloor covering after work hours when an area is subject to much lowertraffic.

The second type of failure occurs if there is an excessive force in onedirection. If such a force is imparted on the connector, the adhesiveconnector will fail altogether and “bunch up” underneath the modularflooring unit causing a “profiling” underneath that can be seen abovethe surface of the modular flooring unit.

Furthermore, the Scott et al. type prior art connector may only be usedwith modular floor covering units having a proprietary backing (e.g., acomposite glass backing) that is used in the manufacturing process.

There also exist other carpet seaming methods for joining together twosegments of floor covering material along long, straight seams. Suchmethods include CARPET SEAMING APPARATUS AND METHOD OF UTILIZING THESAME, U.S. Pat. No. 5,800,664, issued Sep. 1, 1998 (Covert), and SEAMINGAPPARATUS AND METHOD, U.S. patent application Ser. No. 14/309,632, filedJun. 19, 2014, (LeBlanc et al.), both of which are incorporated hereinby reference in their entirety. Additional methods exist for securingmodular floor covering units together in a “floating floor”configuration that overcomes the problems and issues presented by theScott et al. prior art. Such methods include MODULAR CARPET SEAMINGAPPARATUS AND METHOD, U.S. patent application Ser. No. 14/618,752, filedFeb. 10, 2015, (Lautzenhiser et al.) which is incorporated herein byreference in its entirety.

Additionally, problems exist with the manufacture of modular floorcovering units. All flooring coverings are cut into sections. Thesections may be strips 12 feet in length and one to two feet wide, 24″by 24″ square carpet tiles, or carpet strips or tiles in otherstandardized or custom lengths and widths. Flooring and in particularcommercial flooring, which may be modular flooring units (e.g., carpet,vinyl, resilient flooring (vinyl composition tiles (VCT), luxury vinylflooring (LVF), luxury vinyl tile (LVT) or luxury vinyl plank (LVP)),and hardwood), or carpet strips, is under constant stress at its seamsdue to any number of stresses on the seam. The stresses may include subfloor moisture and spills, glue degradation, stress caused by themovement of heavy objects, excessive foot traffic, temperature changes,or other environmental factors.

Currently modular flooring carpet, and in some instances broadloomcarpet, is typically manufactured from a tufted carpet layer, a scrimlayer, and a bonding agent layer. First, the bonding agent is created byfirst blending either a proprietary or standardized blend of rawmaterials that may be either pelletized or powered or both. The type ofmaterials used may vary and depends on the intended use of the carpetbut may include PVC, polypropylene, rubber, fiber glass, graphite, andvarious other compounds. Carpet or modular carpet for the carpet layeris typically tufted and further comprises a primary backing as part ofthe carpet layer. Initially, the carpet comprises the tufted fabric witha primary backing. The carpet enters the manufacturing line pre tuftedand may be on a 12′ or 15′ roll. The carpet roll is then put through aseries of rollers to be stretched out to the desired tension. Thistensioning reduces the likelihood of wrinkles forming in the finishedcarpet when the secondary backing is bound to the tufted fabric andprimary backing later in the manufacturing process.

At the same time as the tufted fabric is being tensioned, a roll ofscrim tape, which may comprise a fiberglass scrim tape, is alsosimilarly tensioned. The pellet and powder mix described above is alsoblended and heated to form a semi solid compound that may have aviscosity and consistency similar to a caulking material. The fiberglassscrim tape, which is under a tension force and stretched flat on anassembly line, is constantly moving at a set forward speed through theassembly process.

The blended semi solid compound is squirted out of nozzles directly ontothe fiber glass scrim tape and subsequently squeegeed to a desiredheight and thickness. The squeegeeing process is guided by a set of edgedividers. This process causes the semi-solid compound to join with andbe pressed into the fiberglass scrim tape, forming a single fiber tapeand semi-solid compound layer. This fiber glass scrim with thesemi-solid compound is then compressed beneath the aforementioned tuftedfabric by a series of rollers forming a sandwiched layer of tuftedfabric, primary backing, semi-solid compound, and fiberglass scrim tape.After these components have been joined or bonded together, the layersare baked in an oven at a constant temperature while still being movedalong the assembly line. After the baking process, one or more coatingsmay be applied to the now finished backing system and carpet roll. Afterthe compression and baking stages of the process, the now finishedcarpet moves on to be laser cut. The cut carpet is then buffed on theedges to remove the stray tufts of fabric and bits of scrim or “fuzzies”from said cut carpet. The aforementioned manufacturing process istypically used for manufacturing modular flooring carpet units.

Carpet manufactured according to the aforementioned process is subjectto a curling force at its edges due in part to the process involved inmanufacturing the carpet. This curling stress adds to the externalstresses on carpet seams. This type of curling stress is particularlyproblematic in modular flooring applications. Typically as part of themanufacturing process broadloom carpet or modular flooring goes througha heat up and cool down process in an environmental chamber that occursafter the primary assembly of the carpet or modular flooring unit iscomplete, i.e., after the carpet has been compressed, baked, and cut.The environmental chamber will change the relative humidity andtemperature from one extreme to another, e.g., high to low or low tohigh, causing the carpet to curl in a particular direction. Dependingupon which direction the carpet curls, the batch of carpet will undergoa process wherein the exact opposite curling will be applied to thecarpet. Applying this type of treatment and curling process to thecarpet reduces the probability of the edges of the carpet curling up atthe seams after installation of said carpet.

Additionally with some existing magnetic floor covering systems, thefloor coverings must be installed in a certain direction relative to theunderlayment as the systems are anisotropic and may only be installed inone particular orientation.

In the field of wall coverings, the process of constructing wallcoverings is time consuming, expensive, and messy. In typicalresidential and commercial buildings, a frame is erected for interiorwalls. On this frame a set of gypsum, sheetrock, or drywall boards aretypically hung. These drywall boards are attached with screws or nailsto the frame, which may be metal or wood. The boards must then befinished prior to painting. The finishing process for drywall boardstypically involves mudding and taping. Mudding involves applying awet-mix compound to mesh or paper tape that has been applied to theseams of the drywall board. The seams and edges must then be sandedprior to finishing. The finishing of drywall boards typically involvespriming the surface with a primer type paint and then painting on thefinal wall cover on the primed surface. This process creates particulatedust contaminants that are difficult to clean and control. The processalso may create an undesirable chemical smell due to volatile organiccompounds (“VOCs”) present in the paint, primer, and drywall boards.

Other methods of finishing a wall include: using wood boards or panelsincluding “ship-lap” style panels; applying stone, masonry, or brick;applying wall-paper using glue and a decorated paper roll; applying walltrim pieces; and securing thin wooden boards and applying a plastercoating. For any of these methods, it may also be desirable to insulatethe wall by placing an insulation layer for thermal or acousticinsulation behind the finished wall. Insulating is an additional stepthat must be completed prior to finishing the wall and may be timeconsuming and messy.

For all of the above mentioned methods, replacing the covering may bedifficult and time consuming. Replacing a masonry wall covering, forexample, requires extensive demolitions and clean-up. Replacingwall-paper may require replacing the drywall board the paper is securedto. Many of the above methods require destructive removal to replace.

Additionally, gymnasiums, fitness facilities, tennis courts, parks andrecreation and any other like facility all have problems with constantwear and tear from the environment, people etc., and are very hard tomaintain and clean properly. They are also typically single purposedwith no ability to be used for anything but the given activity thesurface was designed for. The underlayment could have a peel and stickadhesive backing, or an attached shock pad needed for some sports, orattached cushion for playgrounds to meet ASTM standards.

Furthermore, in current countertop installations, whether a countertopis granite, stone, tile, laminate, or any other material, it isconventionally applied using a concrete like substance, an epoxy or anadhesive substance that is permanent. Typically, a plywood board is cutinto the shape of the underlying cabinets and is screwed into thecabinets. Then a concrete board is screwed into the substrate board if atile product is going to be the finished layer. Then the finishedproduct is laid upon either the single plywood substrate or dualsubstrate depending on the finished product. In this manner thecountertop is permanently affixed to the cabinets. If an end user wishedto change their countertop, it would be impossible to do without tearingthe countertop back down to the cabinets. In this process there issignificant potential to also damage the underlying cabinets and is atime consuming process leaving the kitchen area unusable for a prolongedperiod of time.

Additionally, in existing roofing systems, whether a roof is coveredwith shingles, metal sheets, terra cotta or other stone, the roof isinstalled over a composite wood and glue type board that has a “tar”paper or other underlayment type material to resist moisture. Thematerials tend to overlap each other and flashing materials are put intocorners and a caulk like material around vents to create a water tightroof. Shingled roofs are made almost exclusively with petro chemical(oil) based products with a grit like sand that has been dyed to aspecific pattern. If a problem occurs in these roof systems it is veryexpensive to identify a problem, because of the “overlapping” of thefinish coat to ensure a water type seal. This is a permanent product andif there is a failure (e.g., leak) large areas must be removed andreplaced all the way down to the substrate. It is often difficult tomatch a repair to the remaining roof structure so that it looksseamless.

What is needed is a direction independent method for installing modularfloor covering units that does not requiring the gluing down of thefloor covering units to provide for simple replacement and re-use of themodular floor covering units whether the floor covering units arecarpet, vinyl flooring, resilient flooring, or hardwood flooring and asystem and method for installing modular wall covering units that doesnot require the use materials that are difficult to install and is easyto replace. Additionally, what is needed is a magnetic directionindependent underlayment configurable in various configurations suitingthe individual facility and a magnetically receptive top coat that isquasi-permanent but is easily removed when the top coat needs to becleaned, has outlived its lifespan, or requires a change in use. Also,what is needed is a modular roofing system that has a magnetic bond,that allows a roof to hold up to various building codes in strength, islighter weight and can be made with other “greener” materials. Moreover,what is needed is a quasi-permanent bond that is strong enough to holdthe finished countertop material in place, but also be removed withlittle to no abatement.

SUMMARY OF INVENTION

The present invention provides a system, apparatus, and method forinstalling direction independent magnetized modular floor covering unitson a magnetized underlay. The present invention provides a system andmethod for the manufacture of magnetic flooring and a method forinstalling a floor covering system that solves seaming and installationproblems of prior art installation methods. The present inventioncomprises a two component system comprising a magnetized underlay and anattracting floor covering unit. The present invention also provides adirection independent modular magnetic wall covering system that is a“complete construction system”. The modular magnetic wall coveringsystem of the present invention may be used to finish a wall without theneed for additional components or layers.

Typically, when installing modular floor covering units onto a subfloorthe modular floor covering units are directly applied to the subfloor,which may be a concrete substrate, or to a vapor barrier underlayalready applied to the subfloor. The modular floor covering units arethen adhered to either the subfloor using one of a variety of methods.In a first method, the modular floor covering units are completely glueddown to the subfloor; this is the prevailing method. In a second method,a clip connector system, which may be called a “floating floor”, isused. Examples of floating floor systems include Scott et al. andLautzenhiser et al. described hereinabove. In the floating floorinstallation method, the floor covering unit is not adhered or attachedto the substrate or subfloor, but is instead attached to adjacent floorcovering units using a connector, e.g., a carpet clip. The presentinvention uses a magnetic underlay that may comprise a two or threelayer underlayment but may also comprise other layer configurations.

The present invention may also be utilized in the automotive industrywhere the floor covering would be cut out into the desired pattern,heated up, and then put into a mold. The floor covering would then becooled to set its shape to the specifications of a particularmanufacturer's car. Before the floor covering unit is heated up, cut,put into the mold, and cooled, the actual floor covering unit would passunder the high powered magnet on the conveyer belt. The carpet mat thatlies on top on the carpeting in the car has a backing. In the backingprocess a powdered alloy would be put into the mix. With this system themolded floor covering unit in a car would make sure that the car matwould stay in place. It would significantly increase passenger safety asthere are many accidents involving a car mat that bunched up suddenly bythe driver moving his/her feet causing the matt to bunch under the carsbrake, clutch, and accelerator pedals.

Currently, in the floor covering unit business, it is not cost effectiveto use advertising on a floor covering unit. Due to the installationcost and the time required to change, it has not been prudent to usethis as an advertising opportunity.

Using the floor covering and underlay of the present invention, adepartment store, for example, could use either modular or rolled floorcovering units and with an advertiser's brand printed onto the finish,coat, or surface of the floor covering unit. Designs could also be woveninto the tufted fabric of the carpet itself, or different colored orpatterned tiles or strips of carpet, vinyl flooring, resilient flooring,or hardwood flooring, could be placed to form designs, patterns, words,etc. When an advertisement campaign is over, or when the store wishes todisplay another advertiser or promote another product or brand, thefloor covering unit can easily be changed out with another one and theold floor covering unit may be stored to be used again at a later date.

Another application of the present invention may for use in the home.For example, if a homeowner has an affinity for a particular sportsteam, or a child loves a certain “favorite” film or TV character, floorcovering units with a pattern, color, or design could be easilyinstalled in the home and replaced when the owner's tastes change. Withconventional floor covering units, a homeowner would not customize theirhome so radically because of the significant labor cost and installationexpertise associated with traditional carpets and floor coverings.Stylized floors with specific designs are typically not used except insituations such as on the floor of football team lockers or specific atcertain department store chains. Using the method and system of thepresent invention, only the floor covering units need to be changed.Each time a new floor covering unit is changed, the same magnetizedunderlayment is utilized. A layman unskilled in carpet installationwould also be able to change the floor covering unit without the help ofa professional installer. With this rapid and inexpensive way of usingfloor covering units, commercial branding or media tie-ins using floorcovering units are available for the first time in a manner that is notcost prohibitive.

For example, a little girl for her 4th birthday may want a “Disney'sTinker Bell” floor covering for her room. At 6 years old her tastes maychange and her favorite character may now be “Winney the Pooh”, and atlater at age 12 it may be her favorite pop band. Using the floorcoverings of the present invention, only the top floor covering wouldneed to be replaced and the underlayment may be used over and over. Thehomeowner would not have to call a floor covering installationspecialist to replace the floor coverings each time tastes changed. Asthe present invention does not require any seaming that would take anexpert to do, the homeowner will be able to replace the floor coveringunit themselves.

The modular magnetic wall covering system of the present invention is abenefit for the construction industry and an improvement over the priorart because it eliminates the need for drywall. Drywall is an imperfectproduct. In construction, a mandated Fire rating must be met for localand municipal codes, sound absorption must be provided, and the drywallmust be properly finished. Drywall must do all of these things and bethe finished layer in a finished wall. The modular magnetic wallcovering system of the present invention eliminates the need for drywalland all of its associated costs by using a wall board comprised of alighter, more fire resistant material such as mineral wool. The presentinvention greatly reduces mold and moisture issues that result frommoisture trapped under flooring materials. In high rise construction,currently wall construction cannot begin until the building has beenhung with exterior glass, cladding, or cast materials. This is becausethe gypsum drywall has a paper layer that is organic in nature. In abuilding system, moisture may become trapped under the floor coveringand permeate the walls. The gypsum absorbs the moisture and the absorbedmoisture may cause mold growth. If a building were to have a water pipebreak, mold may grow on the walls within hours. With the system of thepresent invention, the materials used for wall and floor covering havevery little to no organic materials in them. By having a small organicmaterial component, the present invention drastically reduces oreliminates significant and costly moisture issues. Furthermore,dehumidifiers and/or heaters must be brought into the building processfor gypsum walls in the winter/summer provide for the conditions thateliminate mold growth and enable the gypsum drywall seaming to dry in anacceptable time frame. The ability to work on the inside of a buildingbefore the outside of the building is finished will equate to anenormous time and monetary savings in construction projects.

General contractors and construction companies using the modularmagnetic wall covering system of the present invention may offerresidential and commercial real estate developers a safer product withthe much higher fire ratings than those offered by drywall typeconstruction, green labeling, heating and cooling efficiency, and lowerconstruction costs while providing the consumer with the ability tocustomize their “completely interchangeable box” in which they work andlive. The invention can provide semi-permanent o removable wall unitsand may be used in applications such as conventions and exhibit hallsfor quickly adapting temporary wall structures with a versatile, customwall covering system.

A further benefit of the modular magnetic wall covering system of thepresent invention is that it will enable the use of the “completelyinterchangeable box” system for wall, floor and ceiling coverings. Thesystem and method in the present invention may be employed with themodular magnetic wall covering system of the present invention toprovide a consumer with a room or house that is a “completelyinterchangeable box” that may be customized easily and quickly.Additionally, using magnetic underlayment on multiple surfaces willlower the magnetic sheeting costs through economies of scale to a levelthat could not be matched by any other materials.

The construction industry is moving towards modular construction.Finished products are modularized in factories then the finished goodsare brought to the construction site. The modular magnetic wall coveringunit of the present invention is easier to construct, easier totransport and easier to fix errors with than existing wall finishing orcovering methods. There is a large market for a modular magnetic wallcovering system.

In one embodiment the present invention provides a system for finishinga wall comprising: a set of modular wall covering units comprising aninner attractant layer and a decorative outer layer; a magneticunderlayment comprising anisotropic or isotropic magnetic sheeting; anda support layer comprising a wall board, an insulation layer, and acovering layer.

The system of the above embodiment may further comprise a frame. Thesystem may further comprise wherein the support layer is disposed on theframe. The system may further comprise wherein the decorative layer isadapted to resemble the appearance of tile, plaster, wood, slate,granite, painted wall, wall paper, Venetian plaster, wainscoting, trimwood, branding, logos, or art. The system may further comprise whereinthe magnetic underlayment is permanently bonded to the support layer.The system may further comprise wherein the magnetic underlayment isaffixed to the support layer by an adhesive or by a fastening means. Thesystem may further comprise wherein the magnetic underlayment issupported by a fastening apparatus. The system may further comprisewherein the set of modular floor covering units are adapted to bereleaseably attached to the magnetic underlayment. The system mayfurther comprise wherein the wall board comprises mineral wool. Thesystem may further comprise wherein the covering layer comprises a flameretardant outer layer. The system may further comprise wherein theinsulation layer comprises fire retardant glass fibers. The system mayfurther comprise wherein the support layer does not require finishing.

In another embodiment the present invention provides a method fordecorating a surface comprising: securing a magnetic underlayment tosaid surface; and releaseably attaching a set of modular wall coveringunits to the magnetic underlayment. The method may further compriseattaching a supporting layer to a frame and affixing the magneticunderlayment to the supporting surface.

In another embodiment, the present invention provides a method formanufacturing a magnetic floor underlay comprising: blending a bindingcompound, the binding compound comprising a plasticizer and a metalliccompound; stretching a scrim layer; heating the binding component to asemi-solid state; extruding the binding compound over the scrim layer;spreading the binding compound evenly over the scrim layer; heating thebinding compound and scrim layer to set the binding compound into asolid state; pressing a vapor barrier layer onto the binding compoundand scrim layer forming an underlay; and magnetizing the underlay.

In this embodiment, the metallic compound may comprise iron or steelgranules or powder or any suitable ferromagnetic compound. The bindingcompound may comprise PVC, polypropylene, rubber, fiberglass, graphite,or any other suitable compound blend or binding compound. The scrimlayer may be a fiberglass scrim tape. The spreading may be performed bya squeegee guided by a set of edge dividers. The vapor barrier may be asilicone vapor barrier. The scrim layer may be stretched by a set ofrollers. The vapor barrier may be tensioned by a set of rollers. Thevapor barrier may be pressed into the binding compound and scrim layerby a set of sandwich rollers. The underlay may be magnetized by a set ofmagnetic rollers. The magnetic rollers may comprise Neodymium Iron Boron(NdFeB or NIB), Samarium Cobalt (SmCo), Alnico, Ceramic or Ferrite, orSuper Magnet type magnets. The heating of the binding compound and scrimlayer may be performed by an oven.

In another embodiment, the present invention provides a method formanufacturing a floor covering comprising: blending a binding compound,the binding compound comprising a plasticizer and a metallic compound;stretching a scrim layer; heating the binding component to a semi-solidstate; extruding the binding compound over the scrim layer; spreadingthe binding compound evenly over the scrim layer; pressing a floorcovering layer onto the binding compound and scrim layer; and heatingthe binding compound, scrim layer, and floor covering layer to set thebinding compound into a solid state.

In this embodiment, the metallic compound may comprise iron or steelgranules or powder or any suitable ferromagnetic compound. The bindingcompound may comprise PVC, polypropylene, rubber, fiberglass, orgraphite. The scrim layer may be a fiberglass scrim tape. The spreadingmay be performed by a squeegee guided by a set of edge dividers. Thefloor covering layer may be a tufted carpet layer having a primarybacking. The scrim layer may be stretched by a set of rollers. The floorcovering layer may be tensioned by a set of rollers. The floor coveringlayer may be pressed into the binding compound and scrim layer by a setof sandwich rollers. The heating of the floor covering layer, bindingcompound, and scrim layer may be performed by an oven. The floorcovering layer may be cut into a set of floor covering units or may berolled into a roll. The cutting may be performed by a laser, ceramicsheer, or other suitable cutting methods.

In another embodiment, the present invention provides a system formanufacturing a magnetic underlay, the system comprising: a roll ofscrim material; a set of tensioning rollers adapted to tension the scrimmaterial as it is unrolled; a roll of vapor barrier material; a set oftensioning rollers adapted to tension the vapor barrier material as itis unrolled; a hopper adapted to store a heated binding compound, thebinding compound having a metallic component; a nozzle adapted todispense the binding compound on the scrim material; a squeegee adaptedto evenly distribute the binding compound; an oven adapted to heat thescrim material and binding compound to set the binding compound; a setof rollers adapted to press the vapor barrier material into the bindingcompound and scrim material; and a magnetizer adapted to magnetize themetallic compound in the binding material.

In yet another embodiment, the present invention provides a system formanufacturing a floor covering adapted to be used with a magneticunderlay, the system comprising: a roll of scrim material; a set oftensioning rollers adapted to tension the scrim material as it isunrolled; a roll of floor covering material; a set of tensioning rollersadapted to tension the floor covering material as it is unrolled; ahopper adapted to store a heated binding compound, the binding compoundhaving a metallic component; a nozzle adapted to dispense the bindingcompound on the scrim material; a squeegee adapted to evenly distributethe binding compound; a set of rollers adapted to press the floorcovering material into the binding compound and scrim material; and anoven adapted to heat the scrim material and binding compound to set thebinding compound.

In yet another embodiment, the present invention provides a method forinstalling a floor covering, the method comprising: placing an underlayon a subfloor, the underlay having been magnetized in a manufacturingprocess; and placing a floor covering layer on the magnetized underlay,the floor covering layer comprising a metallic compound embedded in thefloor covering layer in a manufacturing process. The underlay may beplaced on the subfloor in a floating floor configuration or may bedirectly glued to the subfloor in high traffic or heavy wear areas.

In still another embodiment, the present invention provides a system forinstalling a floor covering, the system comprising: an underlay on asubfloor, the underlay having been magnetized in a manufacturingprocess; and a floor covering layer adapted to be placed on themagnetized underlay, the floor covering layer comprising a metalliccompound embedded in the floor covering layer in a manufacturingprocess.

In one embodiment the present invention provides a system for finishinga wall comprising: a set of modular wall covering units comprising aninner attractant layer and a decorative outer layer; a magneticunderlayment comprising an isotropic magnetic sheeting; and a supportlayer comprising a wall board, an insulation layer, and a coveringlayer.

The system may further comprise a frame. The system may further comprisewherein the support layer is disposed on the frame. The system mayfurther comprise wherein the decorative layer is adapted to resemble theappearance of tile, plaster, wood, slate, granite, painted wall, wallpaper, Venetian plaster, wainscoting, trim wood, branding, logos, orart. The system may further comprise wherein the magnetic underlaymentis permanently bonded to the support layer. The system may furthercomprise wherein the magnetic underlayment is affixed to the supportlayer by an adhesive or by a fastening means. The system may furthercomprise wherein the magnetic underlayment is supported by a fasteningapparatus. The system may further comprise wherein the set of modularwall covering units are adapted to be releaseably attached to themagnetic underlayment. The system may further comprise wherein the wallboard comprises mineral wool. The system may further comprise whereinthe covering layer comprises a flame retardant outer layer. The systemmay further comprise wherein the insulation layer comprises fireretardant glass fibers. The system may further comprise wherein thesupport layer does not require finishing.

In one embodiment the present invention provides a method for finishinga wall comprising: attaching a support layer comprising a wall board, aninsulation layer, and a covering layer to a support frame; securing amagnetic underlayment comprising an isotropic magnetic sheeting to thecovering layer of the support layer; and releaseably and magneticallyattaching each of a set of modular wall covering units comprising aninner magnetically receptive layer and a decorative outer layer to themagnetic underlayment.

The method may further comprise wherein the decorative layer is adaptedto resemble the appearance of tile, plaster, wood, slate, granite,painted wall, wall paper, Venetian plaster, wainscoting, trim wood,branding, logos, or art. The method may further comprise wherein themagnetic underlayment is permanently bonded to the support layer priorto attaching the support layer to the support frame. The method mayfurther comprise wherein the magnetic underlayment is affixed to thesupport layer by an adhesive or by a fastening means. The method mayfurther comprise wherein the magnetic underlayment is supported by afastening apparatus. The method may further comprise wherein the wallboard comprises mineral wool. The method may further comprise whereinthe covering layer comprises a flame retardant outer layer. The methodmay further comprise wherein the insulation layer comprises fireretardant glass fibers. The method may further comprise wherein thesupport layer does not require finishing.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to facilitate a full understanding of the present invention,reference is now made to the accompanying drawings, in which likeelements are referenced with like numerals. These drawings should not beconstrued as limiting the present invention, but are intended to beexemplary and for reference.

FIG. 1 is a side cross-section view of an embodiment of a carpet layerand magnetic underlay of the present invention.

FIG. 2 is a cutaway plan view of an embodiment of a carpet layer andmagnetic underlay of the present invention.

FIG. 3 is a detailed cross-sectional view of a carpet layer and magneticunderlay of the present invention.

FIG. 4 is a simplified view of an embodiment of the process formanufacturing a magnetic underlay of the present invention.

FIG. 5 is a simplified view of an embodiment of the process formanufacturing a magnetized carpet layer of the present invention.

FIG. 6 is a side cross-section view of an embodiment of a wall frame,support layer, magnetic underlayment, and wall covering unit of thepresent invention.

FIG. 7 is a front view of three phases in the installation process ofthe present invention.

FIG. 8 is a perspective view of in interchangeable box system comprisingmodular floor and wall covering units according to the presentinvention.

FIG. 9 is a front view of a billboard having a magnetic layer and aplurality of modular decorative panels according to the presentinvention.

FIG. 10 is a perspective view of a swimming pool having a magneticunderlayment and a modular liner panel according to the presentinvention.

FIG. 11 is a perspective view of a typical row house and a row housinghaving modular magnetic wall and roofing panels according to the presentinvention.

FIG. 12 is a perspective view of a cabinet installation having amagnetic layer for securing countertops having a magnetically attractivebacking layer according to the present invention.

FIG. 13 is a perspective view of an athletic field having a magneticunderlayment and a plurality of modular floor panels according to thepresent invention.

FIG. 14 is a perspective view of a cubicle having magneticallyattractive wall panels and modular decorative panels according to thepresent invention.

DETAILED DESCRIPTION

The present invention will now be described in more detail withreference to exemplary embodiments as shown in the accompanyingdrawings. While the present invention is described herein with referenceto the exemplary embodiments, it should be understood that the presentinvention is not limited to such exemplary embodiments. Those possessingordinary skill in the art and having access to the teachings herein willrecognize additional implementations, modifications, and embodiments, aswell as other applications for use of the invention, which are fullycontemplated herein as within the scope of the present invention asdisclosed and claimed herein, and with respect to which the presentinvention could be of significant utility.

With reference now to FIG. 1, a side cross-section view of an embodimentof an installed floor covering unit 100 comprising a floor coveringlayer 110 and magnetic underlay layer 120 is provided. The top layer isthe floor covering layer 110. The floor covering layer 110 is placed onthe magnetic underlay layer 120. The magnetic underlay layer 120comprises the magnetized layer 122 and the vapor barrier 126. Anembodiment of the process for producing the magnetic underlay layer 120is shown in detail in FIG. 4 and an embodiment of the process forproducing the floor covering layer 110 is shown in detail in FIG. 5.

With reference now to FIG. 4, an embodiment of the process 400 formanufacturing a magnetic underlay layer 120 is provided. Three primarycomponents comprise the magnetic underlay layer 120: the fiberglassscrim component 123, shown in FIG. 3, from the roll of fiberglass scrim410, the vapor barrier component 126 from the roll of silicone vaporbarrier 420, and the semi-solid liquid blend 124, shown in FIG. 3, fromthe hopper 430.

The magnetic underlayment 120 may be magnetized to a set number of polesaccording to the process 400. First, a scrim layer 123, made fromfiberglass or various other suitable compounds and blends typically usedin the industry, is unrolled from a roll 410 through a set of rollers412 that stretch and apply a tension to the scrim layer 123. The bottomlayer in this process may be a vapor barrier 126 unrolled from the roll420. The vapor barrier 126 provides the underlayment 120 with moistureresistance. A blending of the compounds described above for themanufacture of a carpet layer, e.g., PVC, polypropylene, rubber, fiberglass, graphite, and various other compounds, is blended in the hopper430. An additional “metal”, metallic, or ferro-magnetic compound whichmay comprise extra fine granules of iron powder or stainless steelpowder or any other ferromagnetic alloy is also combined with themixture in the hopper 430.

The underlay 120 is combined by first stretching the scrim 123 throughrollers 412 and then passing the scrim over a conveyor belt 414 to thehopper 430 and the one or more nozzles 432 containing the compoundblend. The blended raw materials compound with the additional blendedalloys component is heated up to a semi solid form in the hopper 430 andis squirted onto the scrim layer 123 by the one or more nozzles 432.This layer of heated compound is shown as compound layer 124 in FIG. 3.The scrim 123 and compound 124 layers pass underneath a squeegee 434 toevenly distribute the compound layer 124 over the scrim layer 123. Thesqueegee 434 may also press the semi-solid compound layer 124 into thescrim layer 123. Optionally, an additional set of rollers may press thelayers 123 and 124 together to form a cohesive layer of both scrim 123and compound 124. The compound 124 and scrim 123 layers then passthrough oven 440 to set the semi-solid compound layer 124. Theunderlayment is baked at a set temperature and passed through the oven440 at the speed of assembly line belt, causing the compound 124 andscrim 123 layers meld together into the scrim and compound layer 127,shown in FIG. 3, and transition to a solid state.

After passing through the oven 440, a vapor barrier 126 unrolled fromthe roll 420 and tensioned by the rollers 422 is combined with into thescrim and compound layer 127 by the sandwich rollers 452. The now“complete” underlayment 120 then passes over a strong high poweredmagnet(s) roller 450, which may comprise Neodymium Iron Boron (NdFeB orNIB), Samarium Cobalt (SmCo), Alnico, Ceramic or Ferrite, or SuperMagnet type magnets. In another embodiment the powered magnet roller 450may be a pulse magnetizer. The alloy powder that is trapped in the nowsolid raw materials of the compound 124 and scrim 123 layers ispolarized by passing over the magnetized rollers 450. This complete andmagnetized underlayment 120 may then be rolled up and/or modularized.

With reference now to FIG. 5, an embodiment of the process 500 formanufacturing a magnetized carpet layer 110 is provided. First, abonding agent is created by first blending either a proprietary orstandardized blend of raw materials that may be either pelletized orpowered or both in the hopper 530. The type of materials used may varyand depends on the intended use of the carpet but may include PVC,polypropylene, rubber, fiber glass, graphite, and various othercompounds. A metallic alloy component is also added to the compoundblend. The alloy component may be any iron, steel, or other suitableferro-magnetic compound. Carpet or modular carpet for the carpet layer112 is typically tufted and further comprises a primary backing as partof the carpet layer. Initially, the carpet 112 comprises the tuftedfabric with a primary backing. The carpet enters the manufacturing linepre tufted and may be on a 12′ or 15′ roll 520. The carpet 112 isunrolled from the roll 520 is put through a series of rollers 522 to bestretched out to the desired tension. This tensioning reduces thelikelihood of wrinkles forming in the finished carpet 110 when thesecondary backing or scrim layer 114 is bound to the tufted fabric andprimary backing of the carpet layer 112.

At the same time as the tufted fabric 112 is being tensioned by rollers522, a scrim layer 114 is unrolled from a roll of scrim tape 510, whichmay comprise a fiberglass scrim tape, and tensioned by rollers 512. Thepellet and powder mix described above is also blended and heated in thehopper 530 to form a semi solid compound that may have a viscosity andconsistency similar to a caulking material. The fiberglass scrim tape114, which is under a tension force and stretched flat on the assemblyline 514, is constantly moving at a set forward speed through theassembly process.

The blended semi solid compound is squirted out of one or more nozzles532 directly into a compound layer 116 onto the fiber glass scrim tape114 and subsequently squeegeed by squeegee 534 to a desired height andthickness. The squeegeeing process may be guided by a set of edgedividers. The squeegeeing process causes the semi-solid compound 116 tojoin with and be pressed into the fiberglass scrim tape 114, forming asingle fiber tape and semi-solid compound layer 115. This fiber glassscrim with the semi-solid compound layer 115 is then compressed beneaththe tufted fabric layer 112 by a series of rollers 552 forming asandwiched layer of tufted fabric and primary backing 112, semi-solidcompound 116, and fiberglass scrim tape 114. After these components havebeen joined or bonded together by rollers 552, the layers are baked inan oven 550 at a constant temperature while still being moved along theassembly line.

The process 500 combines the alloy into the backing of the finishedfloor covering unit 110. However, after the baking in the oven 550 inthe process 500, unlike after the baking in the process 400, the carpetlayer 110 would not pass over a high powered magnet like magnet 450.After the baking process, one or more coatings may be applied to the nowfinished backing system and carpet roll. The finished product 110 may bekept in a roll or it could be cut into modular floor covering units.After the compression and baking stages of the process, the now finishedcarpet moves 110 may be laser cut. The cut carpet may also be buffed onthe edges to remove the stray tufts of fabric and bits of scrim or“fuzzies” from said cut carpet.

In another embodiment, the underlay 120 or primary backing 112 andsemi-solid compound 114 may be produced as a sheet of material that maybe hot-pressed or otherwise combined with a top layer to produce amagnetic underlayment layer or magnetically receptive layer that may beapplied to or combined with any other layer. In this embodiment theunderlayment layer or magnetically receptive layer may be produced by acalendering method. A calender is a device used to process a polymermelt into a sheet or film. The same method may be used to make amagnetically receptive layer.

The calendar disperses a heat softened polymer (e.g., rubber, PVC)between two or more rollers to form a continuous sheet. To begin theprocess a polymer is first blended and fluxed. Blending is a processthat creates the desired polymer and fluxing heats and works the blendedpolymer to a desired consistency. The polymer is then processed throughthe calender and is extruded at a thickness determined by the gap sizebetween a final set of rollers. The final set of rollers also determinethe surface finish (e.g., glossy, textured). A double sided peel andstick layer or other adhesive layer may also be added to theunderlayment layer or magnetically receptive layer produced by thecalendaring process. A cushion or other insulating layer may also beattached to the underlayment layer or magnetically receptive layerproduced by the calendaring process. The underlayment layer ormagnetically receptive layer produced by the calendaring process may becombined with another layer in a method similar to that shown in FIGS. 4and 5.

When the calendering method is used to produce a magnetic underlayment ablend of materials that may be magnetized must be added to the polymermixture prior to forming the layer. One of iron powder, iron granules,steel granules, steel powder, anisotropic powder, isotropic powder, orstrontium ferrite powder may be added to the polymer mixture. After thecalendered layer is formed it may be magnetized. The calendered layermay then be magnetized by a pulse magnetizer or by a set of magneticrollers.

With reference to FIGS. 1 and 2, a method for installing the modularfloor covering 110 using the magnetized underlayment 120 on a subfloormay be as follows.

The underlayment 120 would first be placed on the subfloor. Theunderlayment 120 may either float, that is not be secured, or may bedirectly glued to the subfloor. The vapor barrier 126 would be placedclosest to the subfloor with the magnetized scrim layer 122 facingupwards, away from the subfloor. The carpet layer 110 with the embeddedmagnetically attractant layer, which may either be a rolled carpet layeror a set of modular flooring units, is placed or laid over theunderlayment 120. Because of the alloy powder in the backing on thecarpet layer 110, the carpet layer 110 will be significantlymagnetically attracted to the underlayment 120. In this way the finishedflooring 100 will not have to be seamed at all. The installation methodaccording to present invention eliminates the need to seam (or hold inplace) the carpet layer 110, which may be either modular flooring unitsor longer rolled goods carpet.

Installing a carpet layer 110 using the magnetized underlayment 120provides several benefits over the prior art. First it solves theproblem of curling floor tiles and broadloom. The carpet layer 110 willalways lay flat due to the magnetic attraction between the underlayment120 and the carpet layer 110. There will be no need to “seam” two piecesof carpet layer 110 together regardless of whether the carpet layer 110is a modular floor covering unit or broadloom rolled goods carpet. Withsufficient magnetization, the carpet layer 110 will resist tensionforces from foot traffic, furniture, machinery, etc. on three axes.

This manufacturing method may be used for most floor coveringapplications and is not be limited to carpet based floor covering units.This same method with small variations may be used with, for example,magnetized underlayment and vinyl flooring; the powdered alloy may beapplied to the backing or it may be added to the vinyl blend during themanufacturing process. A plasticizer or other compound or chemical maybe added to the compound layer to enable the compound layer to eitherstick to or be embedded in the floor covering unit. This system may alsobe used in vinyl composition tiles (VCT), luxury vinyl tile (LVT) orluxury vinyl plank (LVP) tiles, as well as other various floor coveringunits including ceramic tiles, stone tiles, hardwood, laminate wood,engineered hardwood, and porcelain tiles. A similar modified method mayalso be used to manufacture hardwood floor coverings with an embeddedmagnetic or magnetized compound or with a magnetic or magnetizedbacking. A magnetic or magnetized compound or backing as describedherein may be applied to any suitable floor covering. These non-carpetfloor coverings with magnetic layers, backings, or embedded compoundsmay be installed in a manner similar to that used for installing carpetfloor coverings.

With reference now to FIG. 6, a side cross-section view of an embodimentof a modular magnetic wall covering system 600 comprising a wall frame1000, support layer 900, magnetic underlayment 800, and wall coveringunit 800 of the present invention is provided.

The modular magnetic wall covering system 600 may use a support layer900 comprising a wall board 910 that does not need to be finished andalso does not need to be made from Gypsum. The wall board 910 of thepresent invention may be comprised of a lighter, thinner, board, whichin a preferred embodiment is comprised of mineral wool. Mineral wool isa premium insulation product—made from volcanic rock melted at hightemperatures and spun into a mat or batt of fine fibers. Mineral woolonly burns at temperatures in excess of 850 Celsius so in effect is veryresistant to fire and provides a fire barrier for a roof, walls, orfloor. A mineral wool wall board 910 dramatically increases the firerating and the R value for insulating and acoustics over a traditionalgypsum drywall board. The support layer 900 does not have to be finishedlike a drywall board would. Because of this, the support layer 900 maycomprise different materials than a typical drywall board. The supportlayer 900 may comprise a wall board 910 which may comprise mineral wool,a cover layer 930 which may comprise a fire retardant webbing, and aninsulation layer 920 which may comprise acoustic dampening raw materialsheeting. The cover layer 930, insulation layer 920, and wall board 910may be incorporated into one sheet as a support layer 900 because thesupport layer 900 does not need to be the “finish coat” like drywallwhich must be hung, finished, primed, textured and then finally painted.

The magnetic underlayment 800 is disposed between the support layer 900and the wall covering unit 700 and abuts the cover layer 930 of thesupport layer if one is used or the wall board 910 if no insulationlayer 920 or cover layer 930 are used. The magnetic underlayment 800 maybe attached to the wall board by a fastener, such as nails, stapes,screws, or clips, or by adhesives such as glues, silicone adhesives,etc. The magnetic underlayment may also be fastened to the support layer900 and/or the wall frame 1000 by a fastener device 600 shown in FIG. 2.The magnetic underlayment 800 may be anisotropic or isotropic magneticsheeting. The magnetic underlayment 800 is applied over the supportlayer 900. Optionally, the magnetic underlayment 800 may be incorporatedinto the support layer 900 in a single board removing the need toseparately attach, hang, or affix the magnetic underlayment o thesupport layer 900. The support layer 900 and magnetic underlayment 800together as a single board have a high R value and substantially reduceunwanted noise pollution and echo.

In the support layer 900, mineral wool with a hardening additive such asfiberglass may be used to give the board comparable stiffness to agypsum board. Not only does mineral wool have desirable acousticproperties, but the magnetic underlayment 800, which may compriseanisotropic powder for stronger magnetic remanence, but may beisotropically independent to the magnetically receptive material, is anadditional sound barrier in the system. Mineral wool is an inertmaterial and provides many advantages when used in buildingconstruction. Mineral wool insulation may be made from basalt—an igneousrock.

A support layer 900 primarily comprised of mineral wool or slag woolwould eliminate most mold and/or moisture issues that result fromtrapped moisture under flooring materials. In high rise construction,currently wall construction cannot begin until the building has beenhung with the exterior glass and cast materials. This is because ofproblems that exist with typically used gypsum based walls. Furthermore,dehumidifiers and/or heaters must be brought into the building processfor gypsum walls in the winter/summer to remove the conditions thatallow for mold growth and provide the ability to allow the seaming ofthe gypsum boards to dry in an acceptable time frame. The ability towork on the inside of a building before the outside of the building isfinished using a mineral wool support layer 900 will result in time andmonetary savings in construction.

The outer layer is the wall covering unit 700 which is the “finishcoat”. The wall covering unit 700 may be manufactured in a mannersimilar to a resilient flooring product. The wall covering unit 700 mayhave an attractant layer 720 hot pressed as a backing to a decorativesurface layer 710. The top layer or outer layer of the modular magneticwall covering system 600 is the decorative surface layer 710, the“Décor” layer. The decorative surface layer 710 may be made to imitatethe appearance of any surface or covering type. The finish of thedecorative surface layer 710 may be virtually any finish as desired bythe end user such as tile, plaster, wood, slate, granite, flat or mattecolor, wall paper, Venetian plaster, traditional wainscoting and trimwood, brands, art etc. Since there is no traffic on the modular wallcovering unit 700, it may be manufactured thinner than a similarly sizedmodular floor covering unit.

With reference now to FIG. 7, a front view of three phases in theinstallation process of the modular magnetic wall covering system 600 ofthe present invention is provided. The wall frame 1000 comprising a setof wood, metal, or plastic frame members 510 is the support structurefor the modular magnetic wall covering system 600. A support layer 900comprising only a wall board 910 is secured to the frame using fasteners940 which may be screws, nails, staples, or other suitable fasteningmeans. The magnetic underlayment 800 is affixed to the support layer 900and would be disposed on the front of the surface layer 900 and behindthe back of the modular wall covering units 700. As described herein,the magnetic underlayment may be affixed to the support layer 900 byfasteners such as fastening units 600 or by adhesives. Fastening units1100 may be preferred over adhesives to provide additional support forthe weight of the magnetic underlayment 800 and wall covering units 700to prevent sagging or drooping. The wall covering units 700 withdecorative outer layers 710 may be placed on the magnetic underlayment800 after the magnetic underlayment 800 is affixed to the support layer900. Additional trim pieces such as trim piece 1200 may be used to hideseams, provide additional support, or provide decoration. The trim piece1200 may be placed anywhere along the magnetic underlayment 800including at the middle as a wainscoting or chair rail, at the top as acrown molding, or at the bottom as a baseboard.

The modular magnetic wall covering system 600 of the present inventionis not limited to being used on boards such as the support layer 900 orin new construction. The modular magnetic wall covering system 600 ofthe present invention may be used on any suitable magnetic underlayment800. The magnetic underlayment 800 may be installed on existing wallboards such as drywall or on ceilings or other existing walls orsurfaces. For example, a magnetic underlayment 800 may be installed onthe collapsible walls of a convention center divider or above doors,openings, or walkways. A wall covering unit 700 could then be easilyplaced and removed on the magnetic underlayment 800 as desired.

With reference now to FIG. 8, a perspective view of a room having aninterchangeable box system 1300 is provided. The interchangeable boxsystem 1300 combines features of the wall covering system 600 andmodular floor covering 100. The magnetic underlayment 800 on the wallsis adapted to receive wall covering units 700, trim pieces 1200, and mayalso be adapted to mount additional fixtures such as television 1310either directly or by a frame or other supporting structure affixed tothe television and magnetically secured on the underlayment 800. Thefloor of the interchangeable box system 1300 comprises the underlayment120 and a set of floor covering layers 110. A room implementing theinterchangeable box system 1300 may have any aspect of the floors orwalls changed and redecorated with minimal effort and would not requiredemolition or tear down of existing decorations or fixtures. Toconstruct a room with the interchangeable box system 1300 a supportlayer 900, shown in FIG. 7, would be attached to a wall frame. Themagnetic underlayment 800 could be attached to the support layer, thesupport layer could be impregnated with a magnetic component, a magneticunderlayment 800 could be laminated to the exterior of the support layer900, or the support layer 900 could be fully coated in a magneticallyattractive coating. Wall covering units 700, trim pieces 1200, and otherfixtures may then be magnetically, semi-permanently, and releaseablysecured to the magnetic underlayment 800. The underlayment 120 for themodular floor covering 100 may be secured to a supporting surface asdescribed hereinabove. Floor covering units 110 may then be placed onthe underlayment 120. Additionally, a magnetic underlayment may beattached to a ceiling in a similar manner to the underlayment 800 on thewalls. Ceiling tiles may be secured to the ceiling underlayment in asimilar manner to the wall covering units 700.

The magnetic underlayment 800 and underlayment 120 may have thefollowing properties: thickness of 0.060 inches (1.52 mm), hardness ofShore D60, specific gravity of 3.5, a shrinkage 1.5% caused by heatingat 158 F for seven days, tensile strength of 700 psi (49 Kg/cm̂2), andmay have parallel poles (north south) along the length at 2.0 mmintervals. The floor covering unit 110 and wall covering unit 600 mayhave a magnetically isotropic receptive material laminated onto thesurface to be placed on the underlayment 120 or magnetic underlayment800 respectively while the underlayments may either use an anisotropicor istropically magnetized flexible layer laminated onto or incorporatedin the underlayment at the time of manufacture. Specifically, themanufacturing process described above in FIGS. 4 and 5 may use pulsemagnetization to isotroprically magnetize the underlayment 120 ormagnetic underlayment 800. Pulse magnetization utilizes a coil and a setof capacitors to create short “pulse” bursts of energy to slowlyincrease the magnetic field and to completely penetrate the underlayment120 or magnetic underlayment 800. The pulse magnetization may also beused to anisotropically magnetize the underlayment 120 or magneticunderlayment 800 if desired.

If the magnetically attractive layer is incorporated into theunderlayment 120 or underlayment 800, a dry mixture of strontium ferritepowder and rubber polymer resin (e.g., rubber, pvc, or other likematerials to make a thermoplastic binder), is mixed, calendered andground then formed by a series of rollers to give it the correct widthand thickness. The material is then magnetized on one side only as shownabove in FIG. 4.

The magnetic performance of bonded magnets is limited by the amount ofpolymer used (typically between 20-45% by volume) as this significantlydilutes the remanence of the material. In addition, the melt-spun powderhas an isotropic microstructure. The dilution effect is overcome byincorporating an anisotropic magnetic powder. By inducing texture in themagnetic powder or milling it to a fine micrometer-scale particle size,and then preparing the magnet in an aligning field, the bonded magnetcan then have an enhanced remanence in a particular direction. In thepresent invention, the magnetic underlayment, such as underlayment 120or underlayment 800, is magnetized directionally to give it a strongerremanence. However, the magnetically receptive sheeting is not poleoriented and therefore does not need to be oriented in any onedirection. The optimal temperature range for long term durability of theunderlayment 120 or underlayment 800 is from 95 C to −40 C.

For an extruded flexible magnet, the flexible granular material isheated until it begins to melt and is then forced under high pressureusing a screw feed through a hardened die which has been electricaldischarge machine (EDM) wire eroded to have the desired shape of thefinished profile. Flexible magnets can be extruded into profiles whichcan be coiled into rolls and applied or combined as shown in FIGS. 4 and5. The non-magnetized face of a flexible magnet may be laminated with adouble sided adhesive tape, or laminated with a thin vinyl coating sothat a printed layer may be applied. An attached cushion may also beapplied for flooring purposes. Anisotropic permanent flexible magnetsmay have a Residual Magnetic Flux Density (Br) of T(G): 0.22 to 0.23 or(2250-2350) and a Holding Power (BHC) of 159 to 174 kA/m or 2000-2180(Oe) while Isotropic permanent flexible magnets have a residual magneticflux density (Br) of 0.14 to 0.15 T or 1400-1550 (G) and a holdingpower(BHC) of 100 to 111 kA/m or 1250-1400 (Oe). An Anisotropicpermanent flexible magnet may be 40% stronger in magnetic remanence thenan Isotropic one.

For the floor covering units 110 and wall covering units 700, themagnetically receptive material of the attractant layer 720 orsemi-solid compound 116, shown in FIGS. 6 and 3 respectively, may havethe following properties: a thickness of 0.025 inches (0.64 mm), ahardness of Shore D60, a specific gravity of 3.5, a shrinkage 1.5%caused by heating at 158 F for seven days, tensile strength of 700 psi(49 Kg/cm̂2), and a hold strength of 140 grams/cm̂2.

In the interchangeable box system 1300 all components are “quasi”permanently secured to the underlayment. Due to the immense surface areathe magnetic resonance between the underlayment 120 or underlayment 800and the floor covering unit 110 or wall covering unit 700, the materialshave an extremely strong bond, making the installation “quasi”permanent. However, the bond may be broken by “catching” a corner andprying upwards to break the bond, thereby allowing the floor coveringunit 110 or wall covering unit 700 to be changed on demand, somethingcurrently unavailable with any existing technology. In theinterchangeable box system 1300, any building material with a flatbacking (for optimal magnetic remanence) can be utilized in this system.A floor covering unit 110 made from wood, for example, may also beutilized as a wall covering unit 700 or vice versa.

The ability to remove any piece at any given time during theconstruction process is highly desirable. If a wall panel 700 in theinterchangeable box system 700 does not match correctly or needs to betrimmed, as may be the case in many installations, one can simply removea wall piece 700 and reattach on demand with no abatement.

In the Flooring industry, the prevailing method of seaming a rolledcarpet requires affixing a tack strip on the perimeter of the room, hotmelt taping the seams and stretching or “tensioning” the rolled floorcovering to keep the product in place. This allows for product failureby the actual carpet delaminating due to tension (primary backing of theflooring pulling away from the secondary backing), heat distortion ofthe finished goods, peaking of the seam, etc. There are many ways thatthe conventional method can fail. The system 1300 eliminates all ofthese failures and eliminates the need for tackstrip, as the floorcovering unit 110 no longer has to be tensioned. Magnetic remanence dueto immense surface area, prevents the floor covering unit 110 from“peaking” or moving under stress.

In the event that an existing wall or a new construction wall has adefect; such as a bow or concave limiting magnetic remanence, one couldsimply use a double sided magnetically receptive and magnetic backedshim to alleviate the problem as an accessory to the interchangeable boxsystem. The floor covering units 110 and wall covering units 700 canprovide different designs, logos, textures, colors, acoustic properties,reflective properties, or design elements in a room. The floor coveringunits 110 and wall covering units 700 may also incorporate corporate orother branding or sponsorship information and may be used foradvertising or as signage. Homeowners, business owners, or designers maychange out any aspect of any room using the interchangeable box system1300 on demand at any time.

The flexible nature of the interchangeable box system 1300 would alsoprovide benefits in the film, television, and theatre industries. Inthese industries, TV sets, movie sets and the like are built in amodular fashion and typically emulate a real location in a more costeffective manner. Unfortunately these sets are built for their specificuse on a frame and then that frame must be stored for another “like” useof the same set or a new set must be built each and every time to suitthe scene. With the interchangeable box system 1300, it would be highlycost effective and highly beneficial to change the scene of a room ondemand utilizing the same frames. It is also cost effective in largestudios that must have a western town set for a first scene and then aNew York City set for another scene. The ability to use the same framesbut change the wall coverings 700 and floor covering units 110 tosimulate what is needed would be desirable and cost effective.

With reference now to FIGS. 9 to 14, several additional embodiments ofthe present invention are provided.

FIG. 9 provides a front view of a billboard 1400 having a frame 1410supported by a support pillar 1430. One or more magnetically attractivepanels 1420 are secured to the frame 1410. A plurality of modularmagnetic decorative panels 1440, 1442, and 1440 may be installed on themagnetically attractive panels 1420. The magnetically attractive panels1420 may be constructed in a manner similar to the support panels 900and magnetic underlayment 800 described above and the modular magneticdecorative panels 1440, 1442, and 1440 may be similar to the wall panels700 or modular floor covering units 110. When the modular magneticdecorative panels 1440, 1442, and 1440 are placed on the attractivepanels 1420 a design or designs 1450 will be formed from the outwardface of the modular magnetic decorative panels 1440, 1442, and 1440. Ina typical billboard, poster panels are pasted onto a billboard frame.Once an advertising campaign is finished or the panels need to bechanged, the poster panels are covered with the next advertisementsimage. Hand-painted billboards are painted on plywood panels that aresecured to the frame. Once the campaign is complete, the plywood panelsare whitewashed in preparation for the next design. Replacing designs orimages on existing billboards is time consuming and expensive andrequires constant maintenance. The billboard 1400 of the presentinvention provides a magnetic interchangeable system that allows astronger bond using magnetic remanence. A flexible magnetic sheeting canbe adhered to an underlying substrate, laminated to the substrate as oneboard or any other suitable configuration to form the panels 1420. Aflexible magnetically receptive sheeting with and adhered printablevinyl or other suitable material comprise the modular magneticdecorative panels 1440, 1442, and 1440.

The strong magnetic remanence provided by the present invention reducesthe possibility of failure due to the strength of the magnetic bond. Thebillboard 1400 may also incorporate LED, OLED, LCD, orelectroluminescence embedded in the thermoplastic binder of the modularmagnetic decorative panels 1440, 1442, and 1440 and controlled by acontroller board in the billboard 1400. This could enable spot lightingand sequencing of artwork, logos etc. in the modular magnetic decorativepanels 1440, 1442, and 1440.

FIG. 10 provides a perspective view of a swimming pool 1500 having amagnetic underlayment 1520 and modular liner panels 1530 placed on theexterior surface 1510 of the pool 1500. A ferrite material encased in apolymer binder may also be added into the structure of the exteriorsurface 1510 to eliminate the need for a magnetic underlayment 1520. Inthis configuration the liner panels 1530 would need to be magneticallyattractive. The magnetic underlayment 1520 may either be laminated intothe surface 1510 itself, or adhered as a lining. The panels 1530 couldhave magnetically receptive sheeting as the base layer of the flexiblepanel and may be made from printable vinyl or any other material. Thepanels 1530 could also have ferrite in the extruded mix trapped in apolymer to make the ferrite impervious to rust or any otherconfiguration of materials. The panels 1530 may have designs thatresemble traditional tile, patterns, brands, word art, or any otherfeature that a consumer would desire. The panels 1530 may alsoincorporate LED, OLED, LCD, or electroluminescence embedded in thethermoplastic binder.

FIG. 11 provides a perspective view of a typical row house 1600 having astandard exterior 1602 and a row house 1700 having an exterior 1702 witha modular front facade 1712 and modular roof 1720. One or more modularpanels 1710 may be used on the modular front facade 1712. The panels1710 may comprise a magnetically receptive layer and the facade 1712 maycomprise a flexible magnetic sheeting attached to a support structure ormay comprise a supporting surface with an embedded ferromagnetic layer.The modular roof 1720 may comprise a flexible magnetic sheeting attachedto a support structure or may comprise a supporting surface with anembedded ferromagnetic layer. Roofing tiles 1730 may be magneticallysecured to the roof 1720. Additionally, magnetically secured flashing1734 and gutters or drain spouts 1732 may also be attached to themodular roof 1720. The roof 1720 may either comprise a magnetic layeradhesively secured to a substrate or a substrate layer having magneticproperties such as a mineral wool board with a magnetic coating. Themagnetic layer or outer surface of the roof 1720 is water resistantbecause of the thermoplastic binder that encapsulates the strontiumferrite powder in the underlayment or finish coat. The magnetic sheetingthickness for the roof 1720 is determined based on the magneticremanence desired. For example, a wind shear strength to withstand acategory 5 hurricane before failure. A modular roof 1720, would be madefrom safer, environmentally conscious products and would be easy torecycle. Builders and users would be able to obtain “green” credits fora building system that is not only safer to construct (on theinstallation side) easier to install, easier to replace and cleaner forthe environment, giving the end user endless choices for an overallcheaper product than is currently available.

FIG. 12 provides a perspective view of a cabinet system 1800 having amagnetic layer 1810 for securing countertops 1820 having a magneticallyattractive backing layer. The system 1800 may further comprise amagnetic layer 1812 for securing a backsplash 1822 and a plurality ofcabinet doors 1852 that may have magnetically attractive layers on theexteriors of the doors. A sink cutout 1824 may be placed in thecountertop 1820 and magnetic layer 1810. The top of the cabinets 1850may be laminated with independently directional magnetic sheeting toform the magnetic layer 1810 as a one board system or the magnetic layer1810 could also be glued independently of the substrate or any otherconfiguration. If a tile product is used then the independentlydirectional magnetic sheeting of the magnetic layer 1810 can be adheredto the top of the cabinets 1850 as one unit. If a ceramic tile productis used, a non-sanded grout (which would provide additional support to atile countertop) can be used. When removal is desired for renovation orif breakage of a tile were to occur, a knife can be utilized to cut thenon-sanded grout in between the tiles and the individual tile or theentire countertop 1820 can be removed in a simple, quick andnondestructive manner. A magnetically receptive sheeting can be appliedto the backside of the countertop 1820, whether that layer is a solidpiece of granite, a tile, Formica or any other material that constitutesa finished countertop. The magnetic bond will have enough magneticremanence to hold tremendous weight in place because of the largesurface. This enables the replacement of a countertop 1820 by onlychanging the countertop 1820 in a “nondestructive” way saving anyunderlying substrate(s) and cabinets 1850 from harm. The cabinet system1800 enables an end user to modernize their countertops 1820 withminimal effort, saves a significant amount of time on installation andoffers interchangeability, something not currently possible with theprevailing bonding and installation methods.

FIG. 13 provides a perspective view of a modular athletic surface 1900having a magnetic underlayment 1910 and a plurality of modular floorpanels 1920 forming a floor pattern 1922. For example if a sportscomplex has a sports surface, they currently know the dimensions of thatspace. With a modular magnetic surface 1900, the same space could beutilized for multiple purposes. For example, the sports facility couldhave an indoor tennis court with the modular floor panels 1920 being aspecific color, texture, brands, logos, word art, and lines all in asingle rolled sheeting, much like a resilient flooring product or sheetgood, or in a set of modular panels. When the area is finished for agiven day or use, the floor panels 1920 could be rolled up or removedfor storage and a completely new set of floor panels 1920 could beinstalled quickly for a basketball court for example or any otherconfiguration desired. The ability to have a “quasi” permanent set offloor panels 1920 that can be changed to meet the demands of the desiredfacility would be highly beneficial. This athletic surface 1900 may alsobe rubberized for use in playgrounds or play areas.

FIG. 14 provides a perspective view of a cubicle 2000 havingmagnetically attractive inner 2020 and outer 2022 walls attached to aframe 2010 and modular decorative panels 2030. The cubicle 2000 may alsocomprise a desk surface 2040, cabinet 2050, shelf 2052, and drawers2054. A cubicle is typically made from an alloy, is modular in design,has legs for support, conduit for wiring, and units can be configured innumerous ways and are adaptable for changing office needs. Panels may befree-standing or attached directly to ready-made. Existing panel surfaceoptions provide sound absorption, visibility, and tackable surfaces witha fabric or laminated covering. In the cubicle 2000 of FIG. 14, anisotropically independent magnetic sheeting is applied to the outside ofthe interior 2020 and exterior 2022 walls of the individual pieces thatcomprise the cubicle 2000. In existing cubicles fabric is typicallyglued to the frame or the outside covering is a permanent laminatedcomposite. As described with respect to FIG. 8, the independent magneticorientation of the sheeting can either be glued or otherwise attacheddirectly to the walls 2020 and 2022 or fastened directly the frame 2010that is magnetically receptive in nature. The cubicle 2000 enables abusiness, corporation or individual to change the look and feel and theoffice environment to adapt to their needs, or corporate changes inlogos and designs, events etc. An individual working inside of thecubicle would have the ability to design the inside with any coveringthat may be secured to the magnetic walls 2020 and 2022. For example, anemployee of a corporation could print a photo, secure it to amagnetically receptive thin sheeting and then secure the photo theinterior wall 2020. A business or corporation could change the exteriorwall 2022 of the cubicle 2000 to suit corporate uniformity needs anddemands.

While the invention has been described by reference to certain preferredembodiments, it should be understood that numerous changes could be madewithin the spirit and scope of the inventive concept described. Also,the present invention is not to be limited in scope by the specificembodiments described herein. It is fully contemplated that othervarious embodiments of and modifications to the present invention, inaddition to those described herein, will become apparent to those ofordinary skill in the art from the foregoing description andaccompanying drawings. Thus, such other embodiments and modificationsare intended to fall within the scope of the following appended claims.Further, although the present invention has been described herein in thecontext of particular embodiments and implementations and applicationsand in particular environments, those of ordinary skill in the art willappreciate that its usefulness is not limited thereto and that thepresent invention can be beneficially applied in any number of ways andenvironments for any number of purposes. Accordingly, the claims setforth below should be construed in view of the full breadth and spiritof the present invention as disclosed herein.

What is claimed is: 1) A system for finishing a wall comprising: a setof modular wall covering units comprising an inner attractant layer anda decorative outer layer; a magnetic underlayment comprising anisotropic magnetic sheeting; and a support layer comprising a wallboard, an insulation layer, and a covering layer. 2) The system of claim1 further comprising a frame. 3) The system of claim 1 furthercomprising wherein the support layer is disposed on the frame. 4) Thesystem of claim 1 further comprising wherein the decorative layer isadapted to resemble the appearance of tile, plaster, wood, slate,granite, painted wall, wall paper, Venetian plaster, wainscoting, trimwood, branding, logos, or art. 5) The system of claim 1 furthercomprising wherein the magnetic underlayment is permanently bonded tothe support layer. 6) The system of claim 1 further comprising whereinthe magnetic underlayment is affixed to the support layer by an adhesiveor by a fastening means. 7) The system of claim 1 further comprisingwherein the magnetic underlayment is supported by a fastening apparatus.8) The system of claim 1 further comprising wherein the set of modularwall covering units are adapted to be releaseably attached to themagnetic underlayment. 9) The system of claim 1 further comprisingwherein the wall board comprises mineral wool. 10) The system of claim 1further comprising wherein the covering layer comprises a flameretardant outer layer. 11) The system of claim 1 further comprisingwherein the insulation layer comprises fire retardant glass fibers. 12)The system of claim 1 further comprising wherein the support layer doesnot require finishing. 13) A method for finishing a wall comprising:attaching a support layer comprising a wall board, an insulation layer,and a covering layer to a support frame; securing a magneticunderlayment comprising an isotropic magnetic sheeting to the coveringlayer of the support layer; and releaseably and magnetically attachingeach of a set of modular wall covering units comprising an innermagnetically receptive layer and a decorative outer layer to themagnetic underlayment. 14) The method of claim 13 further comprisingwherein the decorative layer is adapted to resemble the appearance oftile, plaster, wood, slate, granite, painted wall, wall paper, Venetianplaster, wainscoting, trim wood, branding, logos, or art. 15) The methodof claim 13 further comprising wherein the magnetic underlayment ispermanently bonded to the support layer prior to attaching the supportlayer to the support frame. 16) The method of claim 13 furthercomprising wherein the magnetic underlayment is affixed to the supportlayer by an adhesive or by a fastening means. 17) The method of claim 13further comprising wherein the magnetic underlayment is supported by afastening apparatus. 18) The method of claim 13 further comprisingwherein the wall board comprises mineral wool. 19) The method of claim13 further comprising wherein the covering layer comprises a flameretardant outer layer. 20) The method of claim 13 further comprisingwherein the insulation layer comprises fire retardant glass fibers. 21)The method of claim 13 further comprising wherein the support layer doesnot require finishing.